Method of stenciling



I I Oct. 1, .l946.- J. T. PEN'II'ON 2,408,578

METHOD OF STENCILLING Filed Dec. 18, 1942 n\ Lu W/////////////////////////////////////// a wdxa an V W I fli?, zl\ IIIIII 30 Patented Oct. 1, 1946 &408578 UNITED STATES PATEN'I OFFICE METHOD OF STENCILING- Joseph T. PentOmPaSad na, Cali f, Application December 18,'1942, Serial No. 469389 l This invention relates to the production .of designs,' decorations, and indicia such as characters, numerals, etc. and relates more particularlyto methods for stenciling. A general object of-this invention is to provide a simple, commercially practical and particularly effective method for making stenciled signs, stenciled decorations, etc. e i i Another object of this invention is to provide amethod for stencilingin which standardand permanent screens or stencils may be employed from time to time for short runs or for extended production, making it unnecessary to cut temporary stencils or screens for each run and making hand work unnecessary in the case of even very short runs.

Another object' of this invention is to provide a method of the character mentioned in which the stencil is not wet with paint, color or other. material, and remains dry throughout the entire process so that it does not require repeated cleaning and so that it cannot smear or otherwise damage the work.

Another object of this invention is to provide a stenciling method that results in the produc-' tion of clear, distinct, regular lines, a clean uniform ground and clean uniform designs, characters or letters.

Another object of this invention is to provide a stenciling method that employs a resist or masking material that dries without flaking or caking to be readily removable, as by brushing, to assure regular clean-cut lines.

A further object of this invention is to provide amethod of the character referred to including a novel step for removing the dry resist or masking material as the final operation or step of the method.

The various objects and features of my invention will be fully understood from the following detailed description of a typical manner of carrying out the method of the presentinvention,

throughout which description reference is made to the accompanying drawing, in which: u

Fig. 1 is an elevation View of an article or sign made in accordance with the invention Fig. 2;

shows the board or backingfollowing the', 'application of the ground'coat; Fig. 3 isanenlarged fragmentary sectional view illustrating the ground coat on'the board, backing or'body; Fig. 4 is a view s'imilar to Fig. 3. showing the masking material 'on the ground. Fig. 5 is a View similar to Fig. 4 with the screen or Stencil in place showing the resist or masking material removed from certain portions as determined by the Stencil. Fig. 6

carried out in the production of various articles and in the making, ornamenting, marking, etc.

of numerous structures, devices and materials. In the following detailed description I will`describe the invention as employed in the production of a sign, or the like. It is to be understood that this is merely a typical illustrative application. of the method and is not to be construed as limiting or restricting either the scope or the application of the invention. In the drawing the subject or object to be stenciled is re'presentedas a board; or the like, which will be termed-'the body o. The body'lu presents a' flat 'smooth outer surface that is clean and suited to'receive paint; color or a finish of the kind required.

The method of the present invention may be said to comprise, generally, the steps of: providing a suitable ground I l on the body !0, applying a resist or masking material [2 overthe ground ll, removing a portion or. portions only of the mask |2 by the aid of a Stencil !3, applying an outer coat l4 and then removing the remaining masking material' !2 and that portion of the outer coat M which covers said remaining masking material to expose portions !5 of the ground. The ground l l may be provided on the surface of thebody o in any selected or practical manner. In fact, the grund ll may be any selected finish for the body surface that is to receive and retain the outer coat !4. For example, the ground Il maybe the direct smooth surface of thematerial constituting the body I 0. In the case illustrated it will be assumed that the ground ll is a layer or coat of paint or otherfinishing and covering material that dries to present a surface suitable for the reception of the masking material l2 and the outer coat I4. The ground ll is preferably smooth and water proof, or at least waterresistant. In the present case it will be assumed that the ground Il covers the entire upper or outer surface oi the body ill. The material constituting the ground Il may be brushed on, sprayed on or' may be provided on the 'body ll] 'by dipping. The device or body !0 may ,be subjected to heat to 'expedite the drying of the ground coat. In some instances it may be found desirable to employ sheet material as the ground Il, in which case such sheet material is secured on the body I ll by adhesive or by other appropriate means.

The provision of the resist coat or maskng coat !2 is important. The masking coat |2 is a temporary covering or layer of material that may be readily removed by brushing, blowing, or the like, When it has set and dried. The masking layer !2 may be sprayed on, brushed on or applied 'by dipping and preferably covers the entire ground ll or at least the entire area in which the stenciling operation is to be carried on. The composition or physical character of the masking layer !2 is a novel feature of the invention. In accordance With the invention the masking layer !2, when dried, is fria ble, being composed of a fine powder or solid material in a comminuted state and yet is self-sustaining. This layer of divided, powdered or granular material is uniform in teX-ture and is not caked or flaked and is such that it may be brushed off in defined areas, as will be later described. The masking layer !2 or the material of the layer is such that it does not soften, attack, permanently color or otherwise injure the ground coat or ground H. I have found it practical to employ porcelain enamel as the masking material, this porcelain enamel being composed of ground glass, a small percentage of clay and just suicient water to constitute a vehicle to assist in the application of the material. It will be apparent that other divided or comminutedmaterials or granular materials and mixtures of the same may be employed to constitute the friable masking layer l2, for example, chalk, sand and mixtures of the same may be employed With any suitable binder or vehicle. In any case the liquid or vehicle employed is such that it does not attack or injure the ground coat I l and is such that it dries or evaporates to leave the solid matter of the masking material l l in a dry poWdered or divided self-sustaining friable body or layer. The masking material is preferably applied to form an even layer or covering over the ground H. The masking material is permitted or caused to dry and it may be found desirable to subject the unit to a suitable degree of heat to increase the rate of drying of the masking layer. It'is preferred to thoroughly dry the masking layer [2. When dried the masking layer z is a fragile but selfsustaining covering or layer which is made up of divided or granular material and is Without flakes, lumps or cakes.

Subsequent to the completion of the masking operation a selected stencil I 3 is applied over the masking layer !2. It is contemplated that a stencil !3 of permanent character or of any selected or available kind may be used and, of course, the Stencil may be designed to produce any figure, Word, pattern, letter, ornamentation, or the like. In the case illustrated, the Stencil !3 is a flat member such as a sheet of brass, or the like, having openings IE in the shape of the letters 21, Wh'ch are to appear on the finished Stencil or work. The Stencil l3 is laid over the masking layer !2 in the required position and is held firmly in place without movement. While the Stencil !3 is so held the portions of the masking layer !2 exposed or made accessible through the openings !6 are removed. In practice the portions of the masking layer I 2 exposed through the openings [6 of the Stencil |3 may be easily and quickly removed by merely brushing away the exposed material. The divided or poWdered material constituting the fragile friable layer !2 is readily bushecl away through the openings !6 of the Stencil. This brushing operation is carried on in such a manner that the portion l'! of the material !2 which are covered or screened by the Stencil |3 remain undisturbed. Where the masking material !2 is made up of finely divided or finely ground material, and Where the layer is completely dried, as above described, the exposed portions of the layer !2 are brushed away leaving sharp definite margins or edges for thos portions I'I which remain under the stencil !3. In this connection it is important to note r that there are no cakes or flakes which might break out under the stencil or which might protrude from the edges of the Stencil openings !6 to leave ragged, irregular edges of the remaining mask portions ll. Following the materialremoving operation or brushing operation just described the Stencil [3 is removed. This is done in a careful manner so that the remaining masking' material portions ll are undisturbed.

The outer coat !4 is applied subsequent to the removal of the Stencil 83. This operation is performed in such a manner that the remaining portions ll of the masking material !2 are undisturbed. In practice I have found it desirable to spray on the final coat 1.4. Further, in some cases I have found it desirable to give the sign, board or device, a light spray coat particularly over those areas carrying the masking material portions l''. This light coat of paint, or the like, does not penetrate or strike through the material at l'l to reach the ground I l and does not produce disintegration of the masking material but, on the other hand, forms a protectve or retaining skin over the remaining bodies of masking material. The light initial spray or spray coat is permitted to dry for a short time to form an effective protective and sustaining cover for the remaining portions l'l of the maskin material, whereupon the spraying is continued to complete. the coat M. The coat !4 is preferably a paint, or the like, which dries hard and which properly adheres to the ground coat ll. The entire exposed surface of the ground coat Il may be sprayed with the finish coat or outer coat !4. The islands or portions I'l of the masking material form or produce elevations IS. These elevations [8 are clearly illustrated in Fig. 6 of the drawing, Where it will be seen that the outer coat !4 covers the masking material p arts l 'l and the latter produce or cause the elevations IB. Thus, it will be seen that the powdered or comminuted material constituting the portions ll is trapped or sealed under the outer coat !4. I

I may prefer in some applications of the invention to moisten the work prior to the application of the outer coat !4. The purpose of this wetting or moistening of the Work is to place or provide moisture in the masking material portions I'l which are later trapped under the outer coat !4, as described above. In practice Water or any other selected readily evaporated liquid may be sprayed across the face of the work before applying the outer coat !4 and the Work may be dried, as by the application of heat, to remove the moisture from the exposed surfaces of the ground I I and yet leave considerable liquid or moisture in the portions ll of the masking material. When the portions ll of the masking material contain or retain moisture at the time of application of the outer 'coat l4 the outer coat does not so readily adhere to the material of th ticularly true if heat is used to quicken the dryi g of the 'outer coat l4. I The heat generates steam or vapor in the portions ll which steam or vapor breaks outwardly through theouter coat' !4 forming cracks'in the paint of the outer-coat. This faoilitatesthe following step or operation of the method. 5

Wh'en the outer coat `l4 has thoroughlydried or has been thorough y dried by the application of heat, a's above described, the paint` or material of the outercoat M is removedfrom the' portions l'l of the masking material .and the masking material that remains is brushed or wiped off to complete the stenciling operation. It is contemplated that the paint or material of the outer coat |4 may be removed from the portions l'l in any selected or practical manner. Fig. 8 of the drawing illustrates one manner of breaking free the outer coat material from the portions i'l. A roller |9 is rolled back and :t'orth across the surface of the work and suitable pres-' sure is applied to the roller. This operation causes the 'paint or material of the outer coat |4 to crack and break looseon the elevations !8.- Because the elevations l8 are above the level of the remaining surface of the work the rolle'r IS arushes th'e elevations |8 which are only supported by the portions l'l of the friable masking material layer. The roller [9 is rolled back and, forth across the work a few times to break up the elevations Ia and the paint and material of the elevations is brushed or blown away. The friable masking material constituting the portions I 'I does not adhere to the ground [4 but may be brushed or blown away together with' the paint or material thus rolled free. In practice the paint or outer coat material constituting the elevations s breaks free from the outer coat |4 along regular defined lines 20, which Outline or form the margins of the letters or characters 2 I. When the elevations |8 and the portions I 'I of the masking material are removed the ground I I is exposed throughout the areas !5 to constitute the design, numbers, pattern or characters 2I. In this connection it will be apparent that the ground ll and the outer coat l4 may be dillerent in color or nature so that the design, pattern or characters ZI are readily apparent. Figs. 7 and 8 of the drawing show portions of the elevations !8 removed or broken away and show the ground portions !5 exposed to constitute the pattern or characters 2l. Subsequent to th'e above Operations a final protective coat (not shown) of transparent material may be applied over the work if this is necessary or desirable.

It will be observed that the present invention provides a stenciling method in which the stencil [3 remains dry and in which a dry or drying masking material is utilized. The masking material !2 may be very inexpensive, is readily applied and is easily removed during the use of the stencil !3 and during the final operation when the ground portions !5 are being exposed.

Having described only a typical preferred manner of carrying out the method of my invention, I do not wish to be limited or restricted ,to the specific details herein set forth, but wish to reserve to myself any variations or modifications thatmay appear to those skilled in the art; or fall within the scope of the following claims.

Having described my invention, I claim:

1. The heroin 'described method of coating an article 'comprising applying a ground coat, applying a fri'able layer to the ground to completely cover the ground, removing a portion of the layer to expose a portion of the ground, applying a color coat over the remaining portion of said layer andover the exposed portion of the ground, and' then removingthe remaining portion of said layer and the coat thereon.

2. The herein described method of coating an V article comprisingapplying a ground coat, ap-

plylng a friable layer to completely cover the ground-coat, removing a portion of the layer to expose a portion of the ground by arranging astencil over the layer and removing'the'po'rtion of the layer which is left exposed by the stencil, applying a coat which is chromatically different from the ground over the exposed por 'tion of the ground and over the' remaining por tion of the friable layer, and then removing said remaining portion of the layer and the portion of said coat thereon.

3. The method of stenciling on an article which includes applying a ground coat to the article, providing a friable layer completely over the ground, removing given portions of the layer by placing a stencil o -the layer and then removing those portions of the layer which are left exposed by the stencil, removing the stencil, ap plying a coat which is 'chromatically different than the ground to cover the remaining portion of the friable layer and the exposed portion of the ground, and then breaking loose and removing the portion of said coat which covers said remaining portion of the friable layer.

4. The method of stenciling an article which includes providing a ground on the article, providing a friable layer completely over the ground, removing given portions of the layer by placing a stencil over said layer and removing the portions of the layer which are left exposed by the stencil, removing the stencil, applying a coat that will harden and which is chromatically different than the ground to the remaining por tion of said layer and to'the portions of the ground which were exposed by the removal of said given portions of said layer, .breaking free the said coat after it hashardened where it covers the remaining portion of said layer, and then removing said remaining portion of the layer.

5. The method of stenciling an article which includes providing a ground on the article, providing a friable layer completely over the ground by applying to said ground comminuted solid material suspended in a liquid vehicle and causing the liquid to evaporate, removing given portions of the layer by placing a stencil on said layer and removing the portions of the layer which are left exposed by the stencil, removing the stencil, applying a coat which is chromatically different from the ground over the remaining portion of said layer and over the portions of the ground which were exposed by the removal of said given portions of said layer, allowing said coat to harden, breaking free the said coat where it covers the remaining portion of said layer, and then removing said remaining portion of the layer.

6. The method of stenciling an article which includes providing a ground on the article, providing a friable layer completely over the ground by spraying onto the ground finely dividea solid matter in a liquid carrier and then drying out said liquid, removing given portions of the layer by placing a Stencil on said layer and removing the portions of the layer which are left exposed by the Stencil, removing the stencil, applyng a coat which will harden and which is chromatically difierent than the ground over the remaining portion of said layer an over the portions of the ground which were exposed by the removal of said given portions of said layer, allowing said coat to harden, breaking free the said coat where it covers the remaining portion of said layer, and then removing said remaining portion of the layer.

7. The method of stenciling an article which includes providing a ground on the article, providing a friable layer completely over the ground, removing given portions of the layer by placing a Stencil on said layer and removing the portions of the layer which are left exposecl by the stencil, removing the Stencil, applying a coat which will harden and which is chronatically difierent than the ground over the remaining portion of said layer and over the portions of the ground which were exposed by the removal of said given portions of said layer, allowing said coat to harden, breaking free the said coat where it covers the remaining portion of said layer by Operating a roller over the article, and then removing said remaining portion of the layer.

8. The method of stenciling an article which includes providing a ground on the article, providing a friable layer completely over the ground, removing given portions of the layer by placing a- Stencil on said layer and removing the portions of the layer ,which are left exposed by the stencil, removing the Stencil, maistening the remaining portions of said layer, applying a coat of different color value over said remaining portions of said layer and over the exposed portions of the ground, said coat being such as to harden upon being dried, subjecting said coat to heat to dry the same and to Convert the moisture in said remaining portions of said layer into vapor which Cracks and opens the parts of said coat which cover said remaining portions of said laer, and then removing said cracked portions of said coat and the said remaining portions of said layer.

9. The method of stenciling which includes providing a ground on the article to be stenciled, providing a friable layer completely over said ground by spraying thereon a divided solid in a liquid vehicle, removing a given portion of said layer by placing a stencil on the layer and brushing away the portions of the layer which are left exposed by the stencil, removing the Stencil, spraying a coat of paint over the remaining por tion of said layer and over the portions of the ground which were exposed by the removal of said.- portions of the layer, said paint being such as to harden upon being dried, allowing said coat to dry, removing the parts of said coat which cover said remaining portions of said layer, and then removing said remaining portion of said layer.

JOSEPH T. PENTON. 

